Process and apparatus for refining petroleum oil and its distillates



Mar. 3, 1925. 1,528,327

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Patented Mar. 3, 1925.

UNITED STATES PATENT OFFICE.

JOHN HANCOCK, OF WEBSTER GROVES, MISSOURI; MYRTLE c. HANCOCK ADMIN-[STRA- TRIX or SAID JOHN HANCOCK, DECEASED.

PROCESS AND APPARATUS FOR REFINING PETROLEUM OIL AND ITS DISTILLATES.

Application filed November 10, 1919. Serial No. 388,846.

To all whom it may concern:

Be it known that I, JOHN HANCOCK, a citizen of the United States, residing at Webster Groves, in the county of St. Louis and State of Missouri, have invented certain new and useful Improvements in Processes and Apparatus for Refining Petroleum Oil and Its Distillates, of which the following is a specification.

The present invention relates to the art of refining petroleum oil and its distillates, and has particular reference to a novel process and apparatus forreducing the cruder hydrocarbons to synthetic crude oil for use as motor fuel, such as gasoline.

The purpose of the present invention is to provide a relatively simple n21 compact apparatus, and a novel and siigiple process which may be practiced by using this ap paratus for obtaining in a relatively short time the required high grade, petroleum product, and by use of apparatus which may be maintained economically.

Another object of the invention is to pro- 25 vide a process wherein the petroleum oil may be emulsified, cracked and fractionated consecutively and under relatively high temperature through the cracking operation and wherein the collected vapors incident to cracking may be effectually condensed or coolcd prior to the fractionating operation. A further object of the invention is to provide an apparatus and process of this character which is continuous/in operation, or where residues and gas incident to fractionating maybe returned to the original source of emulsifying and retreated-in conjunction with fresh oil for insuring the reduction of the oil in the circuit to the highest ossible degree.

Tie invention also embodies numerous novel means and steps for facilitating and insuring the proper carrying out of the various major steps in the operation to provide, generally, a highly efficient process and apparatus which may bepracticed and operated for the completion of the distillation in a relatively short time.

The above, and various other objects and advantages of this invention will bein part described in, and in part understood from, the following detailed description of the present embodiment of this; invention, the

present preferred apparatus being illustrated in the accompanylng drawings, whereirg: v Fig. 1 is an elevation, partly in section, of a etroleum refining plant constructed accor ing to this invention.

Fig. 2 is a longitudinal section taken centrally through the same.

Fig. 3 is a fragmentary, enlarged elevation, partly in section, of the cracking and cooling portions of the apparatus,

Fig. 4 is a vertical section taken through the emulsifier.

Fig. 5 is a similar View taken through the fractionating tower.

Fig. 6 is a horizontal section taken through the wall structure of the cracking furnace.

F i 7 is a diagrammatic showing of the oil clrcuit through the cracking and condensing portions of the apparatus.

Fig. 8 is a fragmentary, enlarged'elevation of a portion of the cracking furnace.

Fig. 9 is a vertical section through one of the compartments ofthe furnace.

Fig. 10 is a fragmentary sectional view through the upper portion of one of the furnace chambers, illustrating the .outlet for the, products of combustion to the exterior of the chamber.

Fig. 11 is a detail view of the spray nozzle employed in the emulsifier;

Referring to the drawings, wherein like.

parts are designated by similar numerals of reference throughout the several views, and which illustrate a form of apparatus constructed according to the present invention, and by means of which the process of this invention may be carried out, 10-

designates an emulsifier into which the oil to be treated is first delivered, 11 designates a cracking furnace receiving oil in emulsfied form for heating the oil to a high temperature, 12 designates a cooling means adapted to receive the cracked oil, and 13 designates the fractionating tower adapted to receive the cooled cracked oil for separating the reduced vapors therefrom and collecting the condensate for retreatment.

Referring" now to the emulsifier 10, it comprises a stack or tower in the form of a cylindrical bod of desired dimensions and height provide with an upper conical head 14 and a lower conical head or bottom 15.

A suitable base 16, which may be cementitious as shown supports the body 10 and provides means for receiving a steampipe 17 which has a whirling spray nozzle 18 in the apex of the lower head 15 for delivering steam under pressure and in the form of a spray to the body 10, the pressure of the steam being determined by a suitable gage 19 andthe volume being determined by operation of a valve 20. The lower head 15 may be provided with the drain valve 21.

In the lower portion'of the body 10 and above the head 15 is a whirling spray nozzle 22 connected to an oil supply pipe 23 leading from any suitable sourceof oil supply, the volume of oil being controlled by a valve 24 and being measured by a meter 25. The fresh oil is thus sprayed upwardly into the body 10, and a short distance above the oil nozzle 22 is a nozzle 26 connected to a pipe 27 adapted to feed water admixed with a chemical, such as caustic soda or potash for spraying the admixture from the nozzle 26 into the comminuted steam and o-il'mass rising through the body 10. The percentage of the chemical may of course be varied to meet conditions of operation, but theproportion desired is such as to absorb substantially fifteen (15%) per cent of moisture from the mass to augment the emulsifying of the same. A conical baflle pan 28 is positioned in the body 10 above-the zones of the nozzles and is preferably of the per-.

f-orated type for bringing the steam, oil and water with its chemical into intimate contact. The comingled mass is drawn through the top of the body 10 and a pipe 29 to-the crackingapparatus; the flow being regulated valve 30 and measured by a meter 31. The water pipe 27 may be provided with a controlling valve 32 and a meter 33 so that the volume of the various fluids admitted to the bottom of the stack or body may be correctly proportioned to meet conditions found 'in carrying out the process.

The emulsifier is also provided with a nozzle 34 of the whirling spray type which leads from a return pipe 35,; hereinafter referred to, and which also has a controlling valve 36 and a meter 37, by means of which the returned condensate may be determined and regulated. The nozzle 34 is preferaoiy located opposite the fresh oil nozzle 22 and in the same horizontal zone therewith.

The emulsifier is connected to the cracking apparatus or furnace, .and the latter comprises the body art 11 of brick or other desired construction having the usual ex terior enclosing walls, a metal roof 38 and intermediate vertical partitions or walls 39 dividing the furnace into longitudinal coinpartments. The furnace is also provided with transverse partitions 40 which, 1n con junction with thelongitudinal partitions 39,

form superposed pairs of chambers 41 and 42 which respectively form heating and cooling chambers.

As best. shown in Fig. 3, each heating chamber 41 is the upper chamber and is proan asbestos bottom layer or mat 45 and spaced at all .sides from the walls of the heating chamber 41 to form fines or passages thereabout. At one end of the retort 44, and

in the top thereof, is an outlet court or passage 46 which communicates the interior of the retort with the exterior passages thereabout. The heating chamber 41 is provided, at opposite sides of the retort 44 with preheating or cracking tubes 47 in the form of elongated coils which communicate with the feed pipe 29 extending from the emulsifier 10. The pipe 29 extends across and through the lower portions of the heating chambers 41 throughout the width of the furnace 11, and each set of preheating tubes 47 is connected-at.oppositesides of each retort with the feed pipe 29 and controlled by valves 29. r The emulsified oil isth'us simultaneously fed upwardly from the feed pipe into each pair of coils 47. The coils-47 are connected by pipes 48 with superheating coils 7 4 within the retort 44, adjacent the side walls, the pipes 48 connectin- -with the central superheater. coils 49 at t e top of the retort and the superheatenopening downwardly through the retort into a pipe 50 which extends into the lower compartment 42. A delivery pipe 51 traverses the upper ends of the cooling chambers 42 and is connected by the pipes 50 to the respec- 'tive superheaters 49. p

In each cooling chamber 42 is disposed a cooling pan 12 which is preferably spaced I from the walls of the cooling chamber 42 and rising therein to a point near the top thereof. These cooling pans 12 are adapted to contain water admitted to the bdttom thereof from a pipe 52 which is-mounted in the base 16, controlling valves 53 regulating the flow of water to the pans. A drain pipe 54 is also seated in the base 16 and CCOIXP municates through valves 55 with the hottoms of the pans 12 so that a free and continuous circulation of water,- or other cooling mediummay be maintained in each cooling pan. Overflow pipes 56 are connected to the drain pipe 54 and rise in the pans 12 to a suitable safety height to prevent overflow of the pans. In each pan 12 is disposed a coil 57 connected at one end to the pipe 51 and connected at its other end to a discharge pipe 58 which leads from the furnace and has communication with all of the coils 57.

For the purpose of supplyin auxiliary pressure in the cracking tubes4 an emergency pressure pipe 59' is connected to the steam pipe 17 at a point forward of the valve 20 and is carried through the furnace 11 and connected by valves 60 to the respective tubes 47 for supplying steam directly thereto when desired. Between the heating chambers 41 the steam pipe 59 is connected to adjacent tubes '47 by T-couplings 61 which may be embedded in the partitions 39. In thisinstance the valves 60 are arranged between the couplings 61 and the pi e 59 for simultaneously controlling the pressure to adjacent coils.

In each heating chamber 41 there is dis posed one or more burners 62 arranged preferably with a pair in each retort 44 and near the bottom thereof. These burners 62 project from a fuel supply pipe 63 which is provided with a controlling valve 64 and a meter 65 for admitting fuel oil or-gas to the burners 62 for consumption in the retort and heatin chamber 41. As may be best'seen from ig. 2, the burners 62 project into the forward ends of the retorts 44 so that the products of combustion as well as the burning gases are caused to travel rearwardly and through the various coils in the retorts to the rear ends of the latter. Air is fed to the interior of each retort 44 by flues 64 which extend upwardly through the partition floor 43 and the bottom of the adjacent retort to convey air from the cooling chamber directly into the retort. The flues 64 may be of any desired number, and are preferably located immediately beneath, each burner 62 so as to supply air directly to the fuel which is sprayed or otherwise emitted from the burners. The air passes into the lower or cooling chamber 42 through an air inlet'passage 65 in the side of the furnace, the air passing upwardly in the chamber 42 about the pan 12 and into the flues 64. In order to create air currents through all of theretorts 44, the longitudinal partitions 39 are providedwith passages or openings 66 intercommuni'cating the chambers 42 so that air passing through the opening 65 may circulate throughout the lower part of the furnace. The retort coils 49 may be drained of tar or residuum through a suitable outlet or trap 67 arranged in vertical line with the pipe 50 and below the drain pipe 51. Above each trap or drainage device 67 is a valve 68 which may be controlled at the front of the furnace by an elongated valve stem 69.v A. similar valve 70 may be placed above the partition or floor 43 and have a similarly formed valve stem permitting closing of the retort coils 49 from the outlet pipe 51. The furnace is provided with a stack 71 communicating with the rear of the furnace through a flue 72 which opens into the rear ends of the heating chambers 41 so ow and as to take off the products of combustion from the chambers. The flue 72 extends practically entirely around the wall of the furnace and is provided with outlets 73 opening-into the adjacent Heating chambers 41. The flue 72 also extends throughthe longitudinal partitions 39 and thereby establishes communication through the ports 73 between the stack 71 and the interiors of the various heating chambers.

Referring now to Fig. 7, the same shows diagrammatically the retort 44 with the retort or central tubes 49 therein and the preheating tu'bes 47 which are located outside of the retort but within the heatin chamher. The oil after being emulsified passes consecutively through the reheating tubes 47, through the side tubes 74 in the retort, then through the central tubes and through the cooling coil 57 to the outlet pipe 58 which leads to the fractionating tower 13. The furnace 11 is preferably provided with a door 75 in front of each heating chamber 41 to admit access and facilitate care of-the burners 62 and. the cleansing of deposits from the heating chambers.

The emulsified and cracked oil is delivered from the outlet pipe 58 of the furnace to the fractionating tower 13. The pipe 58 opens into a whirling spray nozzle 76 which projects upwardly within the tower 13.and is located between a pair of spaced apart ballie pans 77. The baffle pans are located midway between the top and bottom of the tower, and the latter is closed at opposite ends by an upper head 78 and a "lower head or bottom 79 preferably conical in form. The upper head 78 opens at its apex into an outlet pipe 80 which may lead to a condenser or the like for recovering the vapors which rise in the tower 13. The pipe 80 may be equipped with a condenser box 81 adapted to finally trap any low grade oil which may be carried off with the vapors. The lower head 79 of the tower 13 is adapted to 'receive the condensate or residue and return the same through the pipe 35 to the emulsifying tower 10. A suitable pump 82 may be interposed in the pipe 35 for forcing the returned residue to the emulsifier for maintaining the oil in circuit. until it is thoroughly cracked and reduced to the desired vapor. I

In operation, oil is pumped under pressure from any suitable source of supply into the pipe 23 and sprayed into the bottom of the emulsifier and is forced upwardly therein by steam'delivered through the pipe 17 and nozile 18. The steam and oil in the form of a whirling spray are brought into contact with the water and chemical issuing from the nozzle 26, the entire mass being thoroughly heated and admixed to forman emulsion, such action being augmented by use of the bafile pan 28. The emulsified mass is carried off through the pipe 29 to the cracking furnace and is distributed from the pipe 29 through the side or preheating tubes 47 and through the various coils as above described and as shown inFig. 7 The fuel from -the burners 62 produces an, intense heat Within the retort 44 and raises the temperature of the oil passing'through the re tort tubes to a cracking temperature. The burning fuel passes upwardly and rearwardly through the retort and out of the flue 46 in the top thereof to the heating chamber, the burning gases passing downwardly and laterally about the retort and being distributed about the preheating tubes 47. The products of combustion then find exit through the ports 73 and the flue 72 which. leads to the stack 71.

The cracked oil passes down from the retort tube 49 through pipe 50 to the distrib uting pipe 51. The distributing pipe 51 circulates the oil through the cooling coils 57 and finally through the outlet pipe 58.

The coils 57 are effectively maintained cool by a circulation of water through the pans 12, each pan being in an individual circuit so that cool fresh water is constantly supplied to each pan and the heated water is constantly withdrawn from each pan. After the cracked oil is cooled it is conveyed through the pipe 58 to the fractionating tower 13 where the'vaporsare drawn off through the top of the tower and the residue is collected at the bottom of the tower for retreatment.

As an example of use, the temperature in the emulsifier 10 may be at from 300 to 550 degrees F., and the oil pressure may be delivered at from 40 to 60 pounds with the steam pressure from 7 5 to 100 pounds. The heavy hydrocarbon molecules when forced through the whirlingspray nozzle in a mist comein contact with the steam and chemical solution of caustic'soda, caustic potash, alkali, or the like and absorb some 10 to'15 per cent of the chemical solution as the mass passes into the cracking tubes. A high even temperature is maintained in the furnace and causes the enlarged bubbles of the mass to break into smaller droplets or vapor of" which a large percentage is subsequently converted into motor fuel or gasoline.

Of course the Various temperatures and 1 pressures above stated may be varied to suit conditions of the various fluids which are used in the practice of the process, and various changes and modifications may be made in the structure ofvthe apparatus or plant without departing from the spirit of this invention, such changes and modifications being restricted only by the scope of the following claims.

What is claimed is:

1. That process of reducing petroleum oil which consists in reducing the oil to a whirling spray, passin'gjhe spray of oil into a spray of steam, in ecting a spray of a chemical solution into the mass of oil and steam to emulsify the oil in the presence of the chemical, successively heating the emulsified oil to increasing degrees of temperature tocrack the oil, cooling the product, and fractionating the cooled product.

- 2. In an apparatus for reducing petroleum oil, a cracking'furnace having superposed chambers, a retort arranged in the upper chamber, means for consuming fuel in) the retort, said retort having an outlet opening for the products of combustion to admit passage thereof to the upper chamber about the retort, circulating tubes in the heating chamber and in the retort adapted to receive oil for preheating and heating the. same, a cooling medium in the lower chamber, and means for conducting the heated oil into the lower chamber.

3. In an apparatus for reducing a petroleum oil, a heating furnace having upper and lower chambers therein, a retort within the upper chamber and spaced therefrom to form a passage about the retort, tubes arranged in said'space and in the retort and being connected in circuit for receiving oil, said retort having an outlet passage therein communicating with the pas: sage about the retort, means for burning oil within the retort, the products of combustion being adapted to pass from the retort into the passage thereabout for heating and preheating the tubes, a cooling pan in the lower chamber, means for maintaining a] a coil in the pan adapted to be emersed' in the cooling medium and communicating with said tubes, and means for fractionating the cooled oil delivered from the coil.

4. In an apparatus for reducing petroleum oil, means for reducing the oil" into a whirling spray, means for directing said whirling spray of oil into a spray of steam, means for spraying a chemical solution into the oil and steam, means for successively heating the chemically treated oil to increasing degrees of temperature for cracking the oil, cooling means for the product, and means for fractionating the cooled product.

5. In an troleum oil, a cracking furnace comprising enclosure walls and partition walls forming a plurality of upper and lower heating chambers in the furnace, said walls having flues therein communicating. with apparatus for reducing pesaid chambers, a stack communicating with the products of combustion may pa'ssjinto the chambers andout through said flues,

means for conducting oil through said chambers and retorts for cracking the oil,

cooling means in the lower chambers, means" for conducting the cracked oil from the upper to the lower chambers, and means for fractionating the cooled product.

6. That process of reducing petroleum oil which consists in breaking up the oil, passing the oil into a spray of steam, injecting a spray of chemical solution into a 1 mass of steam to emulsify the oil in the the product, and fractionating the cooling 15 product.

JOHN HANCOCK. 

